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A chaku-chaku line has a series of machines, each equipped with a hanedashi device, or autoejector. This enables the operator working a chaku-chaku line to
- walk up and immediately insert the part he is holding into a machine
- press a start button, and then
- pick up the previously ejected part.
Because the chaku-chaku operator is running several machines, she relies on jidoka (autonomation). If there is a problem on a machine while the operator is away, jidoka stops production, preventing further defects or damage to the machine.
Chaku-chaku is a Japanese Lean term that translates to load-load. This is in reference to process the operator follows-loading machine after machine in a chaku-chaku line with no need to unload.
Because of the rapid nature of the chaku-chaku cell, it will often be comprised of a number of single-function, right-sized machines.
Lean Tools Needed for a Chaku-Chaku Line:
- Hanedashi (autoejector)
- Jidoka (autonomation)
- Andon lights (to signal machine problems)
- Standard Work (to specify the process)
- Kanban (to closely manage the inventory-space for excess inventory may be limited)
- Visual management/5S (the rapid character of a chaku-chaku line means parts and materials must be in the correct location every time)
- Kaizen (chaku-chaku lines take a lot of work to complete)
- Right-sized machines (chaku-chaku cells tend to be single function and compact)
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Other Information You May Be Interested In...
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- Autonomation Autonomation is automation with a human touch. It essentially means that an automated machine has the built in intelligence to identify when there is a problem, shut itself off, and...
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- Machine Cycle Time Machine cycle time is the time a machine actually requires to produce one unit of output. Machine cycle time has three basic components. It has the time to load the...
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[...] our own little lean cell when we check out. She loads the items onto the scanner and scans them (chaku chaku), and I remove and bag them (hanedashi). It’s a superb example of workload [...]